Dynamic clamping assemblies with improved wear characteristics for use in connection with electromechanical surgical instruments

ABSTRACT

A dynamic clamping assembly for use with a surgical instrument including first and second jaws pivotally coupled together and movable between open and closed positions. The dynamic clamping assembly includes first jaw engagement features configured to slidably engage the first jaw and second jaw engagement features configured to slidably engage the second jaw to apply closing motions to the first and second jaws. The first jaw engagement features and/or the second jaw engagement features include a surface coating configured to increase a hardness thereof.

BACKGROUND

The present invention relates to surgical instruments and, in various arrangements, to surgical stapling and cutting instruments and staple cartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings as follows:

FIG. 1 is a perspective view of an electromechanical surgical system;

FIG. 2 is a perspective view of a distal end of an electromechanical surgical instrument portion of the surgical system of FIG. 1;

FIG. 3 is an exploded assembly view of an outer shell feature and the electromechanical surgical instrument of FIG. 2;

FIG. 4 is a rear perspective view of a portion of the electromechanical surgical instrument of FIG. 2;

FIG. 5 is a partial exploded assembly view of a portion of an adapter and the electromechanical surgical instrument of the surgical system of FIG. 1;

FIG. 6 is an exploded assembly view of a portion of the adapter of FIG. 5;

FIG. 7 is a cross-sectional perspective view of a portion of an articulation assembly of an adapter;

FIG. 8 is a perspective view of the articulation assembly of FIG. 7;

FIG. 9 is another perspective view of the articulation assembly of FIG. 8;

FIG. 10 is an exploded assembly view of a loading unit employed in the electromechanical surgical system of FIG. 1;

FIG. 11 is a perspective view of an alternative adapter embodiment;

FIG. 12 is a side elevational view of a portion of a loading unit of the adapter of FIG. 11 with the jaws thereof in an open position;

FIG. 13 is another side elevational view of a portion of the loading unit of FIG. 11 with portions thereof shown in cross-section and the jaws thereof in a closed position;

FIG. 14 is a bottom view of a portion of the loading unit of FIG. 13 with portions thereof shown in cross-section;

FIG. 15 is a perspective view of a portion of the loading unit of FIG. 14 with a portion of the outer tube shown in phantom lines;

FIG. 16 is a cross-sectional view of a proximal portion of another adapter employing various seal arrangements therein;

FIG. 17 is an end cross-sectional view of a portion of the adapter of FIG. 16;

FIG. 18 is a side elevation al view of another adapter;

FIG. 19 is a cross-sectional view of a portion of the adapter of FIG. 18;

FIG. 20 is a rear perspective view of portions of another adapter;

FIG. 21 is a cross-sectional view of another adapter;

FIG. 22 is a perspective view of a portion of another loading unit of an adapter with the jaws thereof in a closed position;

FIG. 23 is a side elevational view of the loading unit of FIG. 22;

FIG. 24 is a perspective view of the loading unit of FIG. 23 after the dynamic clamping assembly has initially contacted positive channel opening features on a channel of the dynamic loading unit;

FIG. 25 is a side elevational view of the loading unit of FIG. 24;

FIG. 26 is another side elevational view of the loading unit of FIGS. 22-25 with the jaws thereof in a fully open position;

FIG. 27 is a side elevational view of a portion of another loading unit of an adapter with the jaws thereof in a fully closed position;

FIG. 28 is another side elevational view of the loading unit of FIG. 27 with the jaws thereof in a partially open position;

FIG. 29 is another side elevational view of the loading unit of FIGS. 27 and 28 with the jaws thereof in a fully open position;

FIG. 30 is a side elevational view of a portion of another loading unit of an adapter with the jaws thereof in a fully open position;

FIG. 31 is another side elevational view of the loading unit of FIG. 30, with the jaws thereof in a partially closed position;

FIG. 32 is another side elevational view of the loading unit of FIGS. 30 and 31, with the jaws thereof in a closed position prior to initiation of a firing stroke;

FIG. 33 is a side elevational view of a portion of another loading unit of an adapter with the jaws thereof in a fully open position;

FIG. 34 is a side elevational view of a portion of another loading unit of an adapter with the jaws thereof in a fully open position;

FIG. 35 is a cross-sectional elevational view of a dynamic clamping assembly embodiment;

FIG. 36 is an end elevational view of a portion of the dynamic clamping assembly of FIG. 35 interacting with an anvil assembly of a loading unit of an adapter shown in cross-section;

FIG. 37 is a cross-sectional view of a body portion of the dynamic clamping assembly of FIG. 36 taken along line 37-37 in FIG. 36;

FIG. 38 is a side elevational view of another dynamic clamping assembly with a portion thereof shown in cross-section;

FIG. 39 is a cross-sectional view of a portion of the dynamic clamping assembly of FIG. 38 taken along line 39-39 in FIG. 38;

FIG. 40 is an exploded perspective assembly view of portions of an articulation locking system embodiment of an adapter;

FIG. 41 is a partial cross-sectional perspective view of a portion of an adapter and the articulation locking system of FIG. 40;

FIG. 42 is a partial top cross-sectional view of the articulation locking system of FIGS. 40 and 41 in an unlocked position;

FIG. 43 is another partial top cross-sectional view of the articulation locking system of FIGS. 40-42 in a locked position;

FIG. 44 is a partial cross-sectional view of a portion of a drive assembly locking system of an adapter in an unlocked position;

FIG. 45 is a partial cross-sectional view of the drive assembly locking system of FIG. 44 with an unfired cartridge loaded in an end effector and the drive assembly locking system in an unlocked position;

FIG. 46 is another partial cross-sectional view of the drive assembly locking system of FIGS. 44 and 45 with an unfired cartridge loaded in the end effector and the drive assembly locking system in an unlocked position and a dynamic clamping assembly thereof starting to move through a closing stroke;

FIG. 47 is another partial cross-sectional view of the drive assembly locking system of FIGS. 44-46 with an unfired cartridge loaded in the end effector and the drive assembly locking system in a firing position ready to start moving through a firing stroke;

FIG. 48 is another partial cross-sectional view of the drive assembly locking system of FIGS. 44-47 after the dynamic clamping assembly has been distally advanced through the firing stroke;

FIG. 49 is another partial cross-sectional view of the drive assembly locking system of FIGS. 44-48 as the dynamic clamping assembly is being retracted but before resuming a starting position;

FIG. 50 is another partial cross-sectional view of the drive assembly locking system of FIGS. 44-48 after the dynamic clamping assembly has been retracted back to the starting position and the drive assembly locking system is in the locked position;

FIG. 51 is a side view of the end effector of FIGS. 44-50 with the dynamic clamping assembly shown in a starting position and the jaws thereof in a fully open position;

FIG. 52 shows the position of a drive lock member of the drive assembly locking system of FIGS. 44-50 in a locked position around the dynamic clamping assembly when in the starting position;

FIG. 53 is a side view of the end effector of FIG. 51 after the dynamic clamping assembly has completed a closure stroke and is in a firing position;

FIG. 54 shows the position of a drive lock member of the drive assembly locking system of FIGS. 44-50 in a locked position around the dynamic clamping assembly in the firing position;

FIG. 55 is a side view of a dynamic clamping assembly and a pivoting lock member of another drive assembly locking system in a locked position prior to installing an unspent cartridge into an end effector of an adapter;

FIG. 56 is another side view of the drive assembly locking system of FIG. 55 with an unspent cartridge supported in position to move the pivoting lock member into an unlocked position;

FIG. 57 is an exploded view of the pivoting lock member and cartridge shown in FIG. 56; and

FIG. 58 is a perspective view of another cartridge embodiment.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various embodiments of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. Patent Applications that were filed on even date herewith and which are each herein incorporated by reference in their respective entireties:

-   U.S. patent application Ser. No. ______, entitled SEALED ADAPTERS     FOR USE WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney Docket     No. END8286USNP/170227; -   U.S. patent application Ser. No. ______, entitled END EFFECTORS WITH     POSITIVE JAW OPENING FEATURES FOR USE WITH ADAPTERS FOR     ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney Docket No.     END8277USNP/170219; -   U.S. patent application Ser. No. ______, entitled SURGICAL END     EFFECTORS WITH CLAMPING ASSEMBLIES CONFIGURED TO INCREASE JAW     APERTURE RANGES; Attorney Docket No. END8278USNP/170220; -   U.S. patent application Ser. No. ______, entitled SURGICAL END     EFFECTORS WITH PIVOTAL JAWS CONFIGURED TO TOUCH AT THEIR RESPECTIVE     DISTAL ENDS WHEN FULLY CLOSED; Attorney Docket No.     END8283USNP/170223; -   U.S. patent application Ser. No. ______, entitled SURGICAL END     EFFECTORS WITH JAW STIFFENER ARRANGEMENTS CONFIGURED TO PERMIT     MONITORING OF FIRING MEMBER; Attorney Docket No. END8282USNP/170221; -   U.S. patent application Ser. No. ______, entitled ADAPTERS WITH END     EFFECTOR POSITION SENSING AND CONTROL ARRANGEMENTS FOR USE IN     CONNECTION WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney     Docket No. END8281USNP/170228; -   U.S. patent application Ser. No. ______, entitled ADAPTERS WITH     FIRING STROKE SENSING ARRANGEMENTS FOR USE IN CONNECTION WITH     ELECTROMECHANICAL SURGICAL INSTRUMENTS; Attorney Docket No.     END8287USNP/170229; -   U.S. patent application Ser. No. ______, entitled ADAPTERS WITH     CONTROL SYSTEMS FOR CONTROLLING MULTIPLE MOTORS OF AN     ELECTROMECHANICAL SURGICAL INSTRUMENT; Attorney Docket No.     END8284USNP/170224; -   U.S. patent application Ser. No. ______, entitled HANDHELD     ELECTROMECHANICAL SURGICAL INSTRUMENTS WITH IMPROVED MOTOR CONTROL     ARRANGEMENTS FOR POSITIONING COMPONENTS OF AN ADAPTER COUPLED     THERETO; Attorney Docket No. END8285USNP/170225; -   U.S. patent application Ser. No. ______, entitled SYSTEMS AND     METHODS OF CONTROLLING A CLAMPING MEMBER FIRING RATE OF A SURGICAL     INSTRUMENT; Attorney Docket No. END8280USNP/170226; -   U.S. patent application Ser. No. ______, entitled SYSTEMS AND     METHODS OF CONTROLLING A CLAMPING MEMBER; Attorney Docket No.     END8335USNP/170231; and -   U.S. patent application Ser. No. ______, entitled METHODS OF     OPERATING SURGICAL END EFFECTORS; Attorney Docket No.     END8298USNP/170218M.

Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a surgical system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

The terms “proximal” and “distal” are used herein with reference to a clinician manipulating the handle portion of the surgical instrument. The term “proximal” refers to the portion closest to the clinician and the term “distal” refers to the portion located away from the clinician. It will be further appreciated that, for convenience and clarity, spatial terms such as “vertical”, “horizontal”, “up”, and “down” may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein can be used in numerous surgical procedures and applications including, for example, in connection with open surgical procedures. As the present Detailed Description proceeds, the reader will further appreciate that the various instruments disclosed herein can be inserted into a body in any way, such as through a natural orifice, through an incision or puncture hole formed in tissue, etc. The working portions or end effector portions of the instruments can be inserted directly into a patient's body or can be inserted through an access device that has a working channel through which the end effector and elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw; however, other embodiments are envisioned in which a staple cartridge is not removable from, or at least readily replaceable from, the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are envisioned in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to permit the end effector to be rotated, or articulated, relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of the tissue to be stapled and the anvil is positioned on a second side of the tissue. The anvil is moved toward the staple cartridge to compress and clamp the tissue against the deck. Thereafter, staples removably stored in the cartridge body can be deployed into the tissue. The cartridge body includes staple cavities defined therein wherein staples are removably stored in the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of a longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of staple cavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. The drivers are movable between a first, or unfired position, and a second, or fired, position to eject the staples from the staple cavities. The drivers are retained in the cartridge body by a retainer which extends around the bottom of the cartridge body and includes resilient members configured to grip the cartridge body and hold the retainer to the cartridge body. The drivers are movable between their unfired positions and their fired positions by a sled. The sled is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end. The sled comprises a plurality of ramped surfaces configured to slide under the drivers and lift the drivers, and the staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. The firing member is configured to contact the sled and push the sled toward the distal end. The longitudinal slot defined in the cartridge body is configured to receive the firing member. The anvil also includes a slot configured to receive the firing member. The firing member further comprises a first cam which engages the first jaw and a second cam which engages the second jaw. As the firing member is advanced distally, the first cam and the second cam can control the distance, or tissue gap, between the deck of the staple cartridge and the anvil. The firing member also comprises a knife configured to incise the tissue captured intermediate the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximal to the ramped surfaces such that the staples are ejected ahead of the knife.

FIG. 1 depicts a motor-driven (electromechanical) surgical system 1 that may be used to perform a variety of different surgical procedures. As can be seen in that Figure, one example of the surgical system 1 includes a powered handheld electromechanical surgical instrument 100 that is configured for selective attachment thereto of a plurality of different surgical tool implements (referred to herein as “adapters”) that are each configured for actuation and manipulation by the powered handheld electromechanical surgical instrument. As illustrated in FIG. 1, the handheld surgical instrument 100 is configured for selective connection with an adapter 200, and, in turn, adapter 200 is configured for selective connection with end effectors that comprise a single use loading unit (“SULU”) or a disposable loading unit (“DLU”) or a multiple use loading unit (“MULU”). In another surgical system embodiment, various forms of adapter 200 may also be effectively employed with a tool drive assembly of a robotically controlled or automated surgical system. For example, the surgical tool assemblies disclosed herein may be employed with various robotic systems, instruments, components and methods such as, but not limited to, those disclosed in U.S. Pat. No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which is hereby incorporated by reference herein in its entirety.

As illustrated in FIGS. 1 and 2, surgical instrument 100 includes a power-pack 101 and an outer shell housing 10 that is configured to selectively receive and substantially encase the power-pack 101. The power pack 101 may also be referred to herein as handle assembly 101. One form of surgical instrument 100, for example, is disclosed in International Publication No. WO 2016/057225 A1, International Application No. PCT/US2015/051837, entitled HANDHELD ELECTROMECHANICAL SURGICAL SYSTEM, the entire disclosure of which is hereby incorporated by reference herein. Various features of surgical instrument 100 will not be disclosed herein beyond what is necessary to understand the various features of the inventions disclosed herein with it being understood that further details may be gleaned from reference to WO 2016/057225 A1 and other references incorporated by reference herein.

As illustrated in FIG. 3, outer shell housing 10 includes a distal half-section 10 a and a proximal half-section 10 b that is pivotably connected to distal half-section 10 a by a hinge 16 located along an upper edge of distal half-section 10 a and proximal half-section 10 b. When joined, distal and proximal half-sections 10 a, 10 b define a shell cavity 10 c therein in which the power-pack 101 is selectively situated. Each of distal and proximal half-sections 10 a, 10 b includes a respective upper shell portion 12 a, 12 b, and a respective lower shell portion 14 a, 14 b. Lower shell portions 14 a, 14 b define a snap closure feature 18 for selectively securing the lower shell portions 14 a, 14 b to one another and for maintaining shell housing 10 in a closed condition. Distal half-section 10 a of shell housing 10 defines a connecting portion 20 that is configured to accept a corresponding drive coupling assembly 210 of adapter 200 (see FIG. 5). Specifically, distal half-section 10 a of shell housing 10 has a recess that receives a portion of drive coupling assembly 210 of adapter 200 when adapter 200 is mated to surgical instrument 100.

Connecting portion 20 of distal half-section 10 a defines a pair of axially extending guide rails 21 a, 21 b that project radially inward from inner side surfaces thereof as shown in FIG. 5. Guide rails 21 a, 21 b assist in rotationally orienting adapter 200 relative to surgical instrument 100 when adapter 200 is mated to surgical instrument 100. Connecting portion 20 of distal half-section 10 a defines three apertures 22 a, 22 b, 22 c that are formed in a distally facing surface thereof and which are arranged in a common plane or line with one another. Connecting portion 20 of distal half-section 10 a also defines an elongate slot 24 also formed in the distally facing surface thereof. Connecting portion 20 of distal half-section 10 a further defines a female connecting feature 26 (see FIG. 2) formed in a surface thereof. Female connecting feature 26 selectively engages with a male connecting feature of adapter 200.

Distal half-section 10 a of shell housing 10 supports a distal facing toggle control button 30. The toggle control button 30 is capable of being actuated in a left, right, up and down direction upon application of a corresponding force thereto or a depressive force thereto. Distal half-section 10 a of shell housing 10 supports a right-side pair of control buttons 32 a, 32 b (see FIG. 3); and a left-side pair of control button 34 a, 34 b (see FIG. 2). The right-side control buttons 32 a, 32 b and the left-side control buttons 34 a, 34 b are capable of being actuated upon application of a corresponding force thereto or a depressive force thereto. Proximal half-section 10 b of shell housing 10 supports a right-side control button 36 a (see FIG. 3) and a left-side control button 36 b (see FIG. 2). Right-side control button 36 a and left-side control button 36 b are capable of being actuated upon application of a corresponding force thereto or a depressive force thereto.

Shell housing 10 includes a sterile barrier plate assembly 60 selectively supported in distal half-section 10 a. Specifically, the sterile barrier plate assembly 60 is disposed behind connecting portion 20 of distal half-section 10 a and within shell cavity 10 c of shell housing 10. The plate assembly 60 includes a plate 62 rotatably supporting three coupling shafts 64 a, 64 b, 64 c (see FIGS. 3 and 5). Each coupling shaft 64 a, 64 b, 64 c extends from opposed sides of plate 62 and has a tri-lobe transverse cross-sectional profile. Each coupling shaft 64 a, 64 b, 64 c extends through the respective apertures 22 a, 22 b, 22 c of connecting portion 20 of distal half-section 10 a when the sterile barrier plate assembly 60 is disposed within shell cavity 10 c of shell housing 10. The plate assembly 60 further includes an electrical pass-through connector 66 supported on plate 62. Pass-through connector 66 extends from opposed sides of plate 62. Pass-through connector 66 defines a plurality of contact paths each including an electrical conduit for extending an electrical connection across plate 62. When the plate assembly 60 is disposed within shell cavity 10 c of shell housing 10, distal ends of coupling shaft 64 a, 64 b, 64 c and a distal end of pass-through connector 66 are disposed or situated within connecting portion 20 of distal half-section 10 a of shell housing 10, and are configured to electrically and/or mechanically engage respective corresponding features of adapter 200.

Referring to FIGS. 3 and 4, the power-pack or the handle assembly 101 includes an inner handle housing 110 having a lower housing portion 104 and an upper housing portion 108 extending from and/or supported on lower housing portion 104. Lower housing portion 104 and upper housing portion 108 are separated into a distal half section 110 a and a proximal half-section 110 b connectable to distal half-section 110 a by a plurality of fasteners. When joined, distal and proximal half-sections 110 a, 110 b define the inner handle housing 110 having an inner housing cavity 110 c therein in which a power-pack core assembly 106 is situated. Power-pack core assembly 106 is configured to control the various operations of surgical instrument 100.

Distal half-section 110 a of inner handle housing 110 supports a distal toggle control interface 130 that is in operative registration with the distal toggle control button 30 of shell housing 10. In use, when the power-pack 101 is disposed within shell housing 10, actuation of the toggle control button 30 exerts a force on toggle control interface 130. Distal half-section 110 a of inner handle housing 110 also supports a right-side pair of control interfaces (not shown), and a left-side pair of control interfaces 132 a, 132 b. In use, when the power-pack 101 is disposed within shell housing 10, actuation of one of the right-side pair of control buttons or the left-side pair of control button of distal half-section 10 a of shell housing 10 exerts a force on a respective one of the right-side pair of control interfaces 132 a, 132 b or the left-side pair of control interfaces 132 a, 132 b of distal half-section 110 a of inner handle housing 110.

With reference to FIGS. 1-5, inner handle housing 110 provides a housing in which power-pack core assembly 106 is situated. Power-pack core assembly 106 includes a battery circuit 140, a controller circuit board 142 and a rechargeable battery 144 configured to supply power to any of the electrical components of surgical instrument 100. Controller circuit board 142 includes a motor controller circuit board 142 a, a main controller circuit board 142 b, and a first ribbon cable 142 c interconnecting motor controller circuit board 142 a and main controller circuit board 142 b. Power-pack core assembly 106 further includes a display screen 146 supported on main controller circuit board 142 b. Display screen 146 is visible through a clear or transparent window 110 d (see FIG. 3) provided in proximal half-section 110 b of inner handle housing 110. It is contemplated that at least a portion of inner handle housing 110 may be fabricated from a transparent rigid plastic or the like. It is further contemplated that shell housing 10 may either include a window formed therein (in visual registration with display screen 146 and with window 110 d of proximal half-section 110 b of inner handle housing 110, and/or shell housing 10 may be fabricated from a transparent rigid plastic or the like.

Power-pack core assembly 106 further includes a first motor 152, a second motor 154, and a third motor 156 that are supported by motor bracket 148 and are each electrically connected to controller circuit board 142 and battery 144. Motors 152, 154, 156 are disposed between motor controller circuit board 142 a and main controller circuit board 142 b. Each motor 152, 154, 156 includes a respective motor shaft 152 a, 154 a, 156 a extending therefrom. Each motor shaft 152 a, 154 a, 156 a has a tri-lobe transverse cross-sectional profile for transmitting rotative forces or torque. Each motor 152, 154, 156 is controlled by a respective motor controller. Rotation of motor shafts 152 a, 154 a, 156 a by respective motors 152, 154, 156 function to drive shafts and/or gear components of adapter 200 in order to perform the various operations of surgical instrument 100. In particular, motors 152, 154, 156 of power-pack core assembly 106 are configured to drive shafts and/or gear components of adapter 200.

As illustrated in FIGS. 1 and 5, surgical instrument 100 is configured for selective connection with adapter 200, and, in turn, adapter 200 is configured for selective connection with end effector 500. Adapter 200 includes an outer knob housing 202 and an outer tube 206 that extends from a distal end of knob housing 202. Knob housing 202 and outer tube 206 are configured and dimensioned to house the components of adapter assembly 200. Outer tube 206 is dimensioned for endoscopic insertion, in particular, that outer tube is passable through a typical trocar port, cannula or the like. Knob housing 202 is dimensioned to not enter the trocar port, cannula of the like. Knob housing 202 is configured and adapted to connect to connecting portion 20 of the outer shell housing 10 of surgical instrument 100.

Adapter 200 is configured to convert a rotation of either of first or second coupling shafts 64 a, 64 b of surgical instrument 100 into axial translation useful for operating a drive assembly 540 and an articulation link 560 of end effector 500, as illustrated in FIG. 10 and as will be described in greater detail below. As illustrated in FIG. 6, adapter 200 includes the proximal inner housing assembly 204 that rotatably supports a first rotatable proximal drive shaft 212, a second rotatable proximal drive shaft 214, and a third rotatable proximal drive shaft 216 therein. Each proximal drive shaft 212, 214, 216 functions as a rotation receiving member to receive rotational forces from respective coupling shafts 64 a, 64 b and 64 c of surgical instrument 100. In addition, the drive coupling assembly 210 of adapter 200 is also configured to rotatably support first, second and third connector sleeves 218, 220 and 222, respectively, arranged in a common plane or line with one another. Each connector sleeve 218, 220, 222 is configured to mate with respective first, second and third coupling shafts 64 a, 64 b, 64 c of surgical instrument 100, as described above. Each connector sleeves 218, 222, 220 is further configured to mate with a proximal end of respective first, second, and third proximal drive shafts 212, 214, 216 of adapter 200.

Drive coupling assembly 210 of adapter 200 also includes a first, a second, and a third biasing member 224, 226, and 228 disposed distally of respective first, second, and third connector sleeves 218, 220, 222. Each biasing members 224, 226, and 228 is disposed about respective first, second, and third rotatable proximal drive shaft 212, 214, and 216. Biasing members 224, 226, and 228 act on respective connector sleeves 218, 222, and 220 to help maintain connector sleeves 218, 222. and 220 engaged with the distal end of respective coupling shafts 64 a, 64 b, and 64 c of surgical instrument 100 when adapter 200 is connected to surgical instrument 100.

Also in the illustrated arrangement, adapter 200 includes first, second, and third drive converting assemblies 240, 250, 260, respectively, that are each disposed within inner housing assembly 204 and outer tube 206. Each drive converting assembly 240, 250, 260 is configured and adapted to transmit or convert a rotation of a first, second, and third coupling shafts 64 a, 64 b, and 64 c of surgical instrument 100 into axial translation of an articulation driver or bar 258 of adapter 200, to effectuate articulation of end effector 500; a rotation of a ring gear 266 of adapter 200, to effectuate rotation of adapter 200; or axial translation of a distal drive member 248 of adapter 200 to effectuate closing, opening, and firing of end effector 500.

Still referring to FIG. 6, first force/rotation transmitting/converting assembly 240 includes first rotatable proximal drive shaft 212, which, as described above, is rotatably supported within inner housing assembly 204. First rotatable proximal drive shaft 212 includes a non-circular or shaped proximal end portion configured for connection with first connector sleeve 218 which is connected to respective first coupling shaft 64 a of surgical instrument 100. First rotatable proximal drive shaft 212 includes a threaded distal end portion 212 b. First force/rotation transmitting/converting assembly 240 further includes a drive coupling nut 244 that threadably engages the threaded distal end portion 212 b of first rotatable proximal drive shaft 212, and which is slidably disposed within outer tube 206. Drive coupling nut 244 is slidably keyed within proximal core tube portion of outer tube 206 so as to be prevented from rotation as first rotatable proximal drive shaft 212 is rotated. In this manner, as the first rotatable proximal drive shaft 212 is rotated, drive coupling nut 244 is translated along threaded distal end portion 212 b of first rotatable proximal drive shaft 212 and, in turn, through and/or along outer tube 206.

First force/rotation transmitting/converting assembly 240 further includes a distal drive member 248 that is mechanically engaged with drive coupling nut 244, such that axial movement of drive coupling nut 244 results in a corresponding amount of axial movement of distal drive member 248. The distal end portion of distal drive member 248 supports a connection member 247 configured and dimensioned for selective engagement with an engagement member 546 of a drive assembly 540 of end effector 500 (FIG. 10). Drive coupling nut 244 and/or distal drive member 248 function as a force transmitting member to components of end effector 500. In operation, as first rotatable proximal drive shaft 212 is rotated, as a result of the rotation of first coupling shaft 64 a of surgical instrument 100, drive coupling nut 244 is translated axially along first rotatable proximal drive shaft 212. As drive coupling nut 244 is translated axially along first rotatable proximal drive shaft 212, distal drive member 248 is translated axially relative to outer tube 206. As distal drive member 248 is translated axially, with connection member 247 connected thereto and engaged with a hollow drive member 548 attached to drive assembly 540 of end effector 500 (FIG. 10), distal drive member 248 causes concomitant axial translation of drive assembly 540 of end effector 500 to effectuate a closure of a tool assembly portion 600 of the end effector 500 and a firing of various components within the tool assembly.

Still referring to FIG. 6, second drive converting assembly 250 of adapter 200 includes second proximal drive shaft 214 that is rotatably supported within inner housing assembly 204. Second rotatable proximal drive shaft 214 includes a non-circular or shaped proximal end portion configured for connection with second coupling shaft 64 c of surgical instrument 100. Second rotatable proximal drive shaft 214 further includes a threaded distal end portion 214 a configured to threadably engage an articulation bearing housing 253 of an articulation bearing assembly 252. Referring to FIGS. 6-9, the articulation bearing housing 253 supports an articulation bearing 255 that has an inner race 257 that is independently rotatable relative to an outer race 259. Articulation bearing housing 253 has a non-circular outer profile, for example tear-dropped shaped, that is slidably and non-rotatably disposed within a complementary bore (not shown) of inner housing hub 204 a. Second drive converting assembly 250 of adapter 200 further includes articulation bar 258 that has a proximal portion that is secured to inner race 257 of articulation bearing 255. A distal portion of articulation bar 258 includes a slot 258 a therein, which is configured to accept a hook 562 the articulation link 560 (FIG. 10) of end effector 500. Articulation bar 258 functions as a force transmitting member to components of end effector 500. In the illustrated arrangement and as further discussed in WO 2016/057225 A1, articulation bearing assembly 252 is both rotatable and longitudinally translatable and is configured to permit free, unimpeded rotational movement of end effector 500 when its first and second jaw members 610, 700 are in an approximated position and/or when jaw members 610, 700 are articulated.

In operation, as second proximal drive shaft 214 is rotated, the articulation bearing assembly 252 is axially translated along threaded distal end portion 214 a of second proximal drive shaft 214, which in turn, causes articulation bar 258 to be axially translated relative to outer tube 206. As articulation bar 258 is translated axially, articulation bar 258, being coupled to articulation link 560 of end effector 500, causes concomitant axial translation of articulation link 560 of end effector 500 to effectuate an articulation of tool assembly 600. Articulation bar 258 is secured to inner race 257 of articulation bearing 253 and is thus free to rotate about the longitudinal axis relative to outer race 259 of articulation bearing 253.

As illustrated in FIG. 6, adapter 200 includes a third drive converting assembly 260 that is supported in inner housing assembly 204. Third drive converting assembly 260 includes rotation ring gear 266 that is fixedly supported in and connected to outer knob housing 202. Ring gear 266 defines an internal array of gear teeth 266 a and includes a pair of diametrically opposed, radially extending protrusions 266 b. Protrusions 266 b are configured to be disposed within recesses defined in outer knob housing 202, such that rotation of ring gear 266 results in rotation of outer knob housing 202, and vice a versa. Third drive converting assembly 260 further includes third rotatable proximal drive shaft 216 which, as described above, is rotatably supported within inner housing assembly 204. Third rotatable proximal drive shaft 216 includes a non-circular or shaped proximal end portion that is configured for connection with third connector 220. Third rotatable proximal drive shaft 216 includes a spur gear 216 keyed to a distal end thereof. A reversing spur gear 264 inter-engages spur gear 216 a of third rotatable proximal drive shaft 216 to gear teeth 266 a of ring gear 266. In operation, as third rotatable proximal drive shaft 216 is rotated, due to a rotation of the third coupling shaft 64 b of surgical instrument 100, spur gear 216 a of third rotatable proximal drive shaft 216 engages reversing gear 264 causing reversing gear 264 to rotate. As reversing gear 264 rotates, ring gear 266 also rotates thereby causing outer knob housing 202 to rotate. Rotation of the outer knob housing 202 causes the outer tube 206 to rotate about longitudinal axis of adapter 200. As outer tube 206 is rotated, end effector 500 that is connected to a distal end portion of adapter 200, is also rotated about a longitudinal axis of adapter 200.

Adapter 200 further includes an attachment/detachment button 272 (FIG. 5) that is supported on a stem 273 (FIG. 6) that projects from drive coupling assembly 210 of adapter 200. The attachment/detachment button 272 is biased by a biasing member (not shown) that is disposed within or around stem 273, to an un-actuated condition. Button 272 includes a lip or ledge that is configured to snap behind a corresponding lip or ledge of connecting portion 20 of the surgical instrument 100. As also discussed in WO 2016/057225 A1, the adapter 200 may further include a lock mechanism 280 for fixing the axial position of distal drive member 248. As can be seen in FIG. 21, for example, lock mechanism 280 includes a button 282 that is slidably supported on outer knob housing 202. Lock button 282 is connected to an actuation bar (not shown) that extends longitudinally through outer tube 206. Actuation bar moves upon a movement of lock button 282. In operation, in order to lock the position and/or orientation of distal drive member 248, a user moves lock button 282 from a distal position to a proximal position, thereby causing the lock out (not shown) to move proximally such that a distal face of the lock out moves out of contact with camming member 288, which causes camming member 288 to cam into recess 249 of distal drive member 248. In this manner, distal drive member 248 is prevented from distal and/or proximal movement. When lock button 282 is moved from the proximal position to the distal position, the distal end of actuation bar moves distally into the lock out (not shown), against the bias of a biasing member (not shown), to force camming member 288 out of recess 249, thereby allowing unimpeded axial translation and radial movement of distal drive member 248.

Returning again to FIG. 6, adapter 200 includes an electrical assembly 290 supported on and in outer knob housing 202 and inner housing assembly 204. Electrical assembly 290 includes a plurality of electrical contact blades 292, supported on a circuit board 294, for electrical connection to pass-through connector of plate assembly of shell housing 10 of surgical instrument 100. Electrical assembly 290 serves to allow for calibration and communication information (i.e., life-cycle information, system information, force information) to pass to the circuit board of surgical instrument 100 via an electrical receptacle portion of the power-pack core assembly 106 of surgical instrument 100. Electrical assembly 290 further includes a strain gauge 296 that is electrically connected to circuit board 294. Strain gauge 296 is mounted within the inner housing assembly 204 to restrict rotation of the strain gauge 296 relative thereto. First rotatable proximal drive shaft 212 extends through strain gauge 296 to enable the strain gauge 296 to provide a closed-loop feedback to a firing/clamping load exhibited by first rotatable proximal drive shaft 212. Electrical assembly 290 also includes a slip ring 298 that is non-rotatably and slidably disposed along drive coupling nut 244 of outer tube 206. Slip ring 298 is in electrical connection with circuit board 294 and serves to permit rotation of first rotatable proximal drive shaft 212 and axial translation of drive coupling nut 244 while still maintaining electrical contact of slip ring 298 with at least another electrical component within adapter 200, and while permitting the other electrical components to rotate about first rotatable proximal drive shaft 212 and drive coupling nut 244.

Still referring to FIG. 6, inner housing assembly 204 includes a hub 205 that has a distally oriented annular wall 207 that defines a substantially circular outer profile. Hub 205 includes a substantially tear-drop shaped inner recess or bore that is shaped and dimensioned to slidably receive articulation bearing assembly 252 therewithin. Inner housing assembly 204 further includes a ring plate 254 that is secured to a distal face of distally oriented annular wall 207 of hub 204 a. Ring plate 254 defines an aperture 254 a therethrough that is sized and formed therein so as to be aligned with second proximal drive shaft 214 and to rotatably receive a distal tip thereof. In this manner, the distal tip of the second proximal drive shaft 214 is supported and prevented from moving radially away from a longitudinal rotational axis of second proximal drive shaft 214 as second proximal drive shaft 214 is rotated to axially translate articulation bearing assembly 252.

Turning next to FIG. 10, in one example, the end effector 500 may be configured for a single use (“disposable loading unit—DLU”) and be similar to those DLU's disclosed in U.S. Patent Application Publication No. 2010/0301097, entitled LOADING UNIT HAVING DRIVE ASSEMBLY LOCKING MECHANISM, now U.S. Pat. No. 9,795,384, U.S. Patent Application Publication No. 2012/0217284, entitled LOCKING MECHANISM FOR USE WITH LOADING UNITS, now U.S. Pat. No. 8,292,158, and U.S. Patent Application Publication No. 2015/0374371, entitled ADAPTER ASSEMBLIES FOR INTERCONNECTING SURGICAL LOADING UNITS AND HANDLE ASSEMBLIES, the entire disclosures of each such references being hereby incorporated by reference herein. It is also contemplated that the end effector 500 may be configured for multiple uses (MULU) such as those end effectors disclosed in U.S. Patent Application Publication No. 2017/0095250, entitled MULTI-USE LOADING UNIT, the entire disclosure of which is hereby incorporated by reference herein.

The depicted surgical instrument 100 fires staples, but it may be adapted to fire any other suitable fastener such as clips and two-part fasteners. In the illustrated arrangement, the end effector 500 comprises a loading unit 510. The loading unit 510 comprises a proximal body portion 520 and a tool assembly 600. Tool assembly 600 includes a pair of jaw members including a first jaw member 610 that comprises an anvil assembly 612 and a second jaw member 700 that comprises a cartridge assembly 701. One jaw member is pivotal in relation to the other to enable the clamping of tissue between the jaw members. The cartridge assembly 701 is movable in relation to anvil assembly 612 and is movable between an open or unclamped position and a closed or approximated position. However, the anvil assembly 612, or both the cartridge assembly 701 and the anvil assembly 612, can be movable.

The cartridge assembly 701 has a cartridge body 702 and in some instances a support plate 710 that are attached to a channel 720 by a snap-fit connection, a detent, latch, or by another type of connection. The cartridge assembly 701 includes fasteners or staples 704 that are movably supported in a plurality of laterally spaced staple retention slots 706, which are configured as openings in a tissue contacting surface 708. Each slot 706 is configured to receive a fastener or staple therein. Cartridge body 702 also defines a plurality of cam wedge slots which accommodate staple pushers 709 and which are open on the bottom (i.e., away from tissue-contacting surface) to allow an actuation sled 712 to pass longitudinally therethrough. The cartridge assembly 701 is removable from channel 720 after the staples have been fired from cartridge body 702. Another removable cartridge assembly is capable of being loaded onto channel 720, such that surgical instrument 100 can be actuated again to fire additional fasteners or staples. Further details concerning the cartridge assembly may be found, for example, in U.S. Patent Application Publication No. 2017/0095250 as well as various other references that have been incorporated by reference herein.

Cartridge assembly 701 is pivotal in relation to anvil assembly 612 and is movable between an open or unclamped position and a closed or clamped position for insertion through a cannula of a trocar. Proximal body portion 520 includes at least a drive assembly 540 and an articulation link 560. In one arrangement, drive assembly 540 includes a flexible drive beam 542 that has a distal end 544 and a proximal engagement section 546. A proximal end of the engagement section 546 includes diametrically opposed inwardly extending fingers 547 that engage a hollow drive member 548 to fixedly secure drive member 548 to the proximal end of beam 542. Drive member 548 defines a proximal porthole which receives connection member 247 of drive tube 246 of first drive converting assembly 240 of adapter 200 when the end effector 500 is attached to the distal end of the adapter 200.

End effector 500 further includes a housing assembly 530 that comprises an outer housing 532 and an inner housing 534 that is disposed within outer housing 532. First and second lugs 536 are each disposed on an outer surface of a proximal end 533 of outer housing 532 and are configured to operably engage the distal end of the adapter 200 as discussed in further detail in WO 2016/057225 A1.

With reference to FIG. 10, for example, anvil assembly 612 includes an anvil cover 630 and an anvil plate 620, which includes a plurality of staple forming depressions. Anvil plate 620 is secured to an underside of anvil cover 630. When tool assembly 600 is in the approximated position, staple forming depressions are positioned in juxtaposed alignment with staple receiving slots of the cartridge assembly 701.

The tool assembly 600 includes a mounting assembly 800 that comprises an upper mounting portion 810 and a lower mounting portion 812. A mounting tail 632 protrudes proximally from a proximal end 631 of the anvil cover 630. A centrally-located pivot member 814 extends from each upper and lower mounting portions 810 and 812 through openings 822 that are formed in coupling members 820. In at least one arrangement, the pivot member 814 of the upper mounting portion 810 also extends through an opening 634 in the mounting tail 632 as well. Coupling members 820 each include an interlocking proximal portion 824 that is configured to be received in corresponding grooves formed in distal ends of the outer housing 532 and inner housing 534. Proximal body portion 520 of end effector 500 includes articulation link 560 that has a hooked proximal end 562. The articulation link 560 is dimensioned to be slidably positioned within a slot in the inner housing. A pair of H-block assemblies 830 are positioned adjacent the distal end of the outer housing 532 and adjacent the distal end 544 of axial drive assembly 540 to prevent outward buckling and bulging of the flexible drive beam 542 during articulation and firing of surgical stapling apparatus 10. Each H-block assembly 830 includes a flexible body 832 which includes a proximal end fixedly secured to the distal end of the outer housing 532 and a distal end that is fixedly secured to mounting assembly 800. In one arrangement, a distal end 564 of the articulation link is pivotally pinned to the right H block assembly 830. Axial movement of the articulation link 560 will cause the tool assembly to articulate relative to the body portion 520.

FIGS. 11-15 illustrate an adapter 200′ that is substantially identical to adapter 200 described above, except for the differences noted below. As can be seen in FIG. 11, the adapter 200′ includes an outer tube 206 that has a proximal end portion 910 that has a first diameter “FD” and is mounted within the outer knob housing 202. The proximal end portion 910 may be coupled to the inner housing assembly 204 or otherwise supported therein in the manners discussed in further detail in WO 2016/057225 A1 for example. The proximal end portion 910 extends proximally from a central tube portion 912 that has a second diameter “SD”. In the illustrated embodiment, an end effector 500 is coupled to a distal end 914 of a shaft assembly 203 or outer tube 206. The outer tube 206 defines a longitudinal axis LA that extends between the proximal end portion 910 and the distal end 914 as can be seen in FIG. 11. As can be seen in FIGS. 10 and 11, an outer sleeve 570 of the proximal body portion 520 of the end effector 500 has a distal end portion 572 and a proximal end portion 574. The proximal end portion 574 has a diameter SD′ that is approximately equal to the second diameter SD of the central tube portion 912. The distal end portion 572 has a third diameter “TD”. In one arrangement, FD and TD are approximately equal and greater than SD. Other arrangements are contemplated wherein FD and TD are not equal, but each are greater than SD. However, it is preferable that for most cases FD and TD are dimensioned for endoscopic insertion through a typical trocar port, cannula or the like. In at least one arrangement (FIG. 11), the outer sleeve 570 is formed with a flat or scalloped side 576 to facilitate improved access within the patient while effectively accommodating the various drive and articulation components of the adapter 200′. In addition, by providing the central tube portion 912 with a reduced diameter may afford the adapter 200′ with improved thoracic in-between rib access.

In at least one arrangement, channel 720, which may be machined or made of sheet metal, includes a pair of proximal holes 722 (FIG. 10) that are configured to align with a pair of corresponding holes 636 in the anvil cover 630 to receive corresponding pins or bosses 638 (FIG. 12) to facilitate a pivotal relationship between anvil assembly 612 and cartridge assembly 701. In the illustrated example, a dynamic clamping assembly 550 is attached to or formed at the distal end 544 of the flexible drive beam 542. The dynamic clamping assembly 550 includes a vertical body portion 552 that has a tissue cutting surface 554 formed thereon or attached thereto. See FIG. 10, for example. An anvil engagement feature 556 is formed on one end of the body portion 552 and comprises an anvil engagement tab 557 that protrudes from each lateral side of the body portion 552. Similarly, a channel engagement feature 558 is formed on the other end of the of the body portion 552 and comprises a channel engagement tab 559 that protrudes from each lateral side of the body portion 552. See FIG. 15.

As indicated above, the anvil assembly 612 includes an anvil plate 620. The anvil plate 620 includes an elongate slot 622 that is configured to accommodate the body portion 552 of the dynamic clamping assembly 550 as the dynamic clamping assembly 550 is axially advanced during the firing process. The elongate slot 622 is defined between two anvil plate ledges 624 that extend along each lateral side of the elongate slot 622. See FIG. 10. As the dynamic clamping assembly 550 is distally advanced, the anvil engagement tabs 557 slidably engage the anvil plate ledges 624 to retain the anvil assembly 612 clamped onto the target tissue. Similarly, during the firing operation, the body portion 552 of the dynamic clamping assembly 550 extends through a central slot in the channel 720 and the channel engagement tabs 559 slidably engage channel ledges 725 extending along each side of the central channel slot to retain the cartridge assembly 701 clamped onto the target tissue.

Turning to FIGS. 13 and 15, the channel 720 defines a docking area generally designated as 730 that is configured to accommodate the dynamic clamping assembly 550 when it is in its proximal most position referred to herein as an unfired or starting position. In particular, the docking area 730 is partially defined by planar docking surfaces 732 that provides clearance between the channel engagement tabs 559 on the dynamic clamping assembly 550 to enable the cartridge assembly 701 to pivot to a fully opened position. A ramped or camming surface 726 extends from a distal end of each of the docking surfaces 732. Ramped surface 726 is engaged by the dynamic clamping assembly 550 in order to move the anvil assembly 612 and the cartridge assembly 701 with respect to one another. Similar camming surface could be provided on the anvil assembly 612 in other embodiments. It is envisioned that ramped surfaces 726 may also facilitate the alignment and/or engagement between channel 720 and support plate 620 and/or cartridge body 702. As the drive assembly 540 is distally advanced (fired), the channel engagement tabs 559 on the dynamic clamping assembly 550 engage the corresponding ramped surfaces 726 to apply a closing motion to the cartridge assembly 701 thus closing the cartridge assembly 701 and the anvil assembly 612. Further distal translation of the dynamic clamping assembly 550 causes the actuation sled 712 to move distally through cartridge body 702, which causes cam wedges 713 of actuation sled 712 to sequentially engage staple pushers 709 to move staple pushers 709 vertically within staple retention slots 706 and eject staples 704 into staple forming depressions of anvil plate 620. Subsequent to the ejection of staples 704 from retention slots 706 (and into tissue), the cutting edge 554 of the dynamic clamping assembly 550 severs the stapled tissue as the tissue cutting edge 554 on the vertical body portion 552 of the dynamic clamping assembly 550 travels distally through a central slot 703 of cartridge body 702. After staples 704 have been ejected from cartridge body 702 and a user wishes to use the same instrument 10 to fire additional staples 704 (or another type of fastener or knife), the user can remove the loading unit 510 from the adapter 200′ and replace it with another fresh or unspent loading unit. In an alternative arrangement, the user may simply remove the spent cartridge body 702 and replace it with a fresh unspent or unfired cartridge body 702.

During use of conventional adapters, debris and body fluids can migrate into the outer tube of the adapter and detrimentally hamper the operation of the adapter articulation and firing drive systems. In egregious cases, such debris and fluids infiltrate into the inner housing assembly of the adapter which may cause the electrical components supported therein to short out and malfunction. Further, due to limited access to the interior of the outer tube of the adapter, such debris and fluids are difficult to remove therefrom which can prevent or reduce the ability to reuse the adapter.

Turning to FIGS. 16 and 17, in one arrangement, at least one first seal 230 is provided between the proximal inner housing assembly 204 and the first rotatable proximal drive shaft 212 to prevent fluid/debris infiltration within and proximal to the proximal inner housing assembly 204. In addition, at least one second seal 232 is provided between the articulation bar 258 and the outer tube 206 to prevent fluid/debris from passing therebetween to enter the proximal inner housing assembly 204. At least one third housing seal 233 may be provided around a hub 205 of the proximal inner housing 204 to establish a seal between the hub 205 and the outer knob housing 202. The first, second, and third seals 230, 232, 233 may comprise, for example, flexible O-rings manufactured from rubber or other suitable material.

In other arrangements, it may be desirable for the first and second seals 230, 232 to be located in the adapter 200 distal to the electronic components housed within the outer knob housing 202. For example, to prevent fluids/debris from fouling/shorting the slip ring assembly 298, it is desirable establish seals between the various moving components of the adapter 200 that are operably supported within the outer tube 206 in a location or locations that are each distal to the slip ring assembly 298, for example. The seals 230, 232 may be supported in the wall of the outer tube and/or in mounting member 234 or other separate mounting member/bushing/housing supported within the outer tube 206 and configured to facilitate axial movement of the distal drive member 248 as well as the articulation bar 258 while establishing a fluid-tight seal between the bushing and/or outer tube and the distal drive member 248 and the articulation bar 258. See FIGS. 18 and 20. In the embodiment illustrated in FIG. 19 for example, the first seal 230 may additionally have wiper features 231 that also slidably engage the distal drive member 248 to prevent fluid/debris D from infiltrating in the proximal direction PD into the proximal inner housing assembly 204. In at least one arrangement to enable debris and fluids that have collected in the outer tube 206 distal to the first and second seals 230, 232, at least two flushing ports 236, 238 are provided within the outer tube 206. See e.g., FIGS. 18 and 20. The axially spaced flushing ports 236, 238 are located distal to the first and second seals 230, 232. A flushing solution (e.g., cleaning fluid, saline fluid, air, etc.) may be entered into one or more port(s) to force the errant debris and fluid out of one or more other port(s).

The ability to open the jaws of an endocutter to a large angle enables more tissue to be placed between them. In addition, having the ability to open the jaws to a larger angle also makes it easier for a user to remove the tissue from between the jaws after the stapling process has been completed which helps to simplify the cartridge reloading process when reloadable units are employed. Thus, it is desirable to optimize the speeds and forces required to open the jaws of an end effector such as an endocutter. In the past, a variety of methods have been employed to open the jaws of an endocutter. In one arrangement, a spring was employed to apply a biasing opening force to the jaws. However, such spring opening arrangements may increase the amount of forces needed to close the jaws. They may also have relatively limited motion and can be difficult to install within the end effector.

FIGS. 22-25 illustrate use of an alternative channel 720′ of a second jaw 700′. The channel 720′ may be identical to channel 720 described above, except for the differences noted below. In the illustrated arrangement, for example, the channel 720′ includes a positive channel opening feature 740 that comprises a ramp surface 742 that is located on each side of a central slot 724 in the channel 720′. Each ramp 742 terminates in a planar upper surface 744. As can be further seen in FIG. 22, a channel ledge 725 is formed on each side of the elongate central slot 724 on the top side of the channel 720′. During the firing operation, the body portion 552 of the dynamic clamping assembly 550 extends through the central slot 724 and the channel engagement tabs 559 slidably engage the channel ledges 725 extending along each side of the central slot 724 to retain the cartridge assembly 701 clamped onto the target tissue.

FIGS. 22 and 23 illustrate a position of the dynamic clamping assembly 550 as it is retracted in the proximal direction PD. As can be seen in those Figures, the channel engagement tabs 559 have not yet contacted the ramps 742 of the positive channel opening features 740. FIGS. 24 and 25 illustrate initial contact of the channel engagement tabs 559 with the ramp portions 742 of the corresponding positive channel opening features 740. As can be seen in FIG. 25 the channel 720′ has started to open (i.e., move away from the anvil assembly 612). FIG. 26 illustrates the position of the dynamic clamping assembly 550 in its starting position wherein the channel 720′ is in its fully open position. As can be seen in that Figure, for example, the channel engagement tabs 559 are in engagement with the planar upper surfaces 744 of the ramps 742. Such arrangement may be employed to open the jaws (anvil assembly 612 and cartridge assembly 701) without the use of a spring or springs. However, other variations are contemplated wherein an opening spring is also employed in addition to the positive channel opening features 740.

FIGS. 27-29 illustrate an alternative arrangement where, in addition to the positive channel opening features 740 on the channel 720′, positive anvil opening features 627 are provided on a proximal end 621 of the anvil plate 620′. The anvil plate 620′ may be identical to anvil plate 620 described above, except for the differences noted below. The positive anvil opening features 627 each comprise an anvil opening ramp 628 provided on each side of the elongate slot 622 (see FIG. 10). As discussed above, the anvil plate has an elongate slot 622 that defines two elongate ledges 624 upon which anvil engagement tabs 557 of the dynamic clamping assembly 550 ride. The positive channel opening features 740 on the channel 720′ are longitudinally offset from the positive anvil opening features 627 on the anvil plate 620′. In the illustrated example, the positive channel opening features 740 on the channel 720′ are distal to the positive anvil opening features 627 on the anvil plate 620′. FIG. 27 illustrates initial contact of the channel engagement tabs 559 with the ramp surfaces 742 of the positive channel opening features 740. For reference purposes, the distance between the distal edge of each channel engagement tab 559 and the jaw axis JA is labeled as distance PDD₁. FIG. 28 illustrates the position of the dynamic clamping assembly 550 after the channel engagement tabs 559 have moved up the ramps 742 onto the planar upper surfaces 744 of the positive channel opening features 740. When in that position, the anvil engagement tabs 557 on the dynamic clamping assembly 550 have contacted the anvil opening ramps 628 of the anvil opening features 627. Thus, comparing the proximal travel distance of the dynamic clamping assembly between FIGS. 27 and 28: PDD₂>PDD₁. FIG. 29 illustrates position of the dynamic clamping assembly 550 after it has moved back to its starting position and the anvil engagement tabs 557 on the dynamic clamping assembly 550 have completely moved past the anvil opening ramps 628 of the anvil opening features 627 and the jaws 700′ and 610′ are in their fully open positions. Thus, comparing the proximal travel distance of the dynamic clamping assembly between FIGS. 28 and 29: PDD₃>PDD₂. Such positive jaw opening features 740, 627 use either/both longitudinal forces to drive the opening of the jaws or orthogonal forces to drive the opening motions. In the above described example, the positive jaw opening features are longitudinally offset. In other arrangements, however, the anvil engagement tabs 557 contact the ramps 628 at approximately the same time that the tabs 559 contact the ramps 742.

Another feature employed by a channel 720″ relates to closure ramps formed on the channel 720″. The channel 720″ may be identical to channel 720′ or 720 described above, except for the differences noted below. As can be seen in FIGS. 30-32, for example, a first closure ramp segment 726 a is formed on each side of the elongate slot (not shown) in the channel 720″. Each first closure ramp segment 726 a transitions into a horizontal plateau ramp segment 727 which in turn transitions into a second closure ramp segment 728. Each second closure ramp segment 728 transitions to a corresponding channel ledge 725. In one arrangement, the slope of each of the first closure ramp segments 726 a is the same as the slope of the second closure ramp segments 728. In other arrangements, the slopes are different. FIG. 30 illustrates the position of the channel engagement tabs 559 on the dynamic clamping assembly 550 when the jaws 610″, 700″are in their fully open position. FIG. 31 illustrates a position of the dynamic clamping assembly 550 after it has been moved distally so as to bring the channel engagement tabs 559 into sliding engagement with the proximal closure ramp segments 726 a so as to begin the jaw closure process. FIG. 32 illustrates another position of the dynamic clamping assembly 550 after it has further moved in the distal direction DD so as to bring the channel engagement tabs 559 into sliding engagement with the plateau ramp segment 727 and prior to starting a firing stroke wherein the channel engagement tabs 559 slidably engage the channel ledges 725 on the channel 720″.

Another desirable attribute for surgical end effectors relates to “jaw aperture”. “Jaw aperture” may refer to the angle between a staple forming surface on the anvil plate and a tissue contacting surface of the staple cartridge. In existing versions of DLU's, SULU's and MULU's, the upper channel engagement feature or tab on the dynamic clamping unit, when the dynamic clamping unit is in its proximal most or starting position, is generally positioned directly above or distal to a jaw pivot axis about which the cartridge assembly pivots relative to the anvil assembly. Such arrangements commonly limit the jaws from opening relative to each other more than 18-23 mm, for example.

One aspect of the present disclosure involves the formation of a “docking” or “parking” area for the dynamic clamping member when the dynamic clamping member is in its proximal most or starting position. For example, FIG. 33 illustrates an end effector 1500 that includes a parking or docking area 730 for the dynamic clamping assembly 550 when the dynamic clamping assembly 550 is in its proximal most or starting position. In accordance with another aspect, as was described above, the dynamic clamping assembly 550 includes a vertically extending body portion 552 and has an anvil engagement feature 556 that comprises an anvil engagement tab or flange 557 that extends from each lateral side of the body portion 552. In addition, the dynamic clamping assembly 550 includes a channel engagement feature 558 that comprises a channel engagement tab or flange 559 that extends laterally from each lateral side of the body portion 552. As used in this context, the term “flange” connotes a planar feature that extends transversely or perpendicularly from the body portion 552. As such, when viewed from an end, the dynamic clamping assembly 550 resembles an I-beam configuration and may be referred to herein as a dynamic I-beam clamping member. As can be seen in FIG. 33, a portion of the channel engagement flanges 559 extend proximal of the pin 638 that pivotally couples the cartridge assembly 701 to the anvil assembly 612 and which defines a jaw pivot axis JA about which the anvil and channel may move between open and closed positions. In addition, although not viewable in FIG. 33, in at least one arrangement, a portion of each of the anvil engagement flanges 557 also extends proximal to the jaw pivot axis JA when the dynamic I-beam clamping assembly 550 is in the parking or starting position. This distance is labeled as distance “PDD₄” in FIG. 33, for example.

A lower end of the body portion 552 of the dynamic I-beam clamping assembly 550 extends through an elongate slot (not shown) in the channel 1720. A first lower surface 1726 is formed on a proximal end 1725 of the channel 1720 on each side of the elongate slot. Each first lower surface 1726 terminates distally in a second closure cam surface or ramp 1727 that corresponds to each channel engagement flange 559 on the dynamic I-beam clamping assembly 550. When the channel engagement flanges 559 engage their corresponding second closure cam surface 1727, the cartridge assembly and the anvil assembly 612 start to close or pivot toward each other by virtue of the interaction of the anvil engagement flanges with corresponding surfaces on the anvil plate and the camming action of the channel engagement tabs with the corresponding second closure cam surfaces 1727 on the channel 1720. Once the dynamic I-beam clamping assembly 550 has moved distally to a point wherein the channel engagement flanges 559 disengage the second closure cam surfaces 1727, the channel engagement flanges 559 engage corresponding third closure surfaces 1728 on the bottom of the channel 1720 to keep the anvil assembly and cartridge assembly closed and resist deflection throughout the firing process (i.e., as the dynamic I-beam clamping assembly is distally advanced through the cartridge assembly 701).

In the illustrated arrangement, when the dynamic I-beam clamping assembly 550 is in the proximal most or starting position, the channel engagement flanges 559 are proximal to the second closure cam surfaces 1727 yet are in contact with the first lower surface 1726 to limit or otherwise restrict the jaws (anvil assembly 612, cartridge assembly 701) to that amount of jaw aperture represented as angle Θ₁ between a staple forming surface 625 on the anvil plate 620 and the tissue contact surface 708 of the cartridge body 702). In the illustrated arrangement, for example, the dynamic I-beam clamping assembly 550 may have to move distally a distance X from the starting position until the channel engagement flanges 559 start to cammingly engage the second closure cam surfaces 1727 to commence the jaw closure process. In that arrangement, the actuation sled 1712 has a length SL and the cartridge body 702 has a nose portion 718 that has a length NL that extends beyond the distal end of the channel 1720.

In accordance with another general aspect, FIG. 34 illustrates another end effector 1500′ that includes a parking or docking area 730′ for the dynamic clamping assembly 550 when the dynamic clamping assembly 550 is in its proximal most or starting position. A first lower surface 1726′ is formed on a proximal end 1725 of the channel 1720′ on each side of the elongate slot. Each first lower surface 1726′ terminates distally in a second closure cam surface or ramp 1727′ that corresponds to each channel engagement flange 559 on the dynamic I-beam clamping assembly 550. When the channel engagement flanges 559 cammingly engage their corresponding second closure cam surface 1727′, the cartridge assembly 701 and the anvil assembly 612 start to close or pivot toward each other by virtue of the interaction of the anvil engagement flanges 557 with corresponding surfaces on the anvil plate 620 and the camming action of the channel engagement flanges 559 with the corresponding second closure cam surfaces 1727′ on the channel 1720′. Once the dynamic I-beam clamping assembly 550 has moved distally to a point wherein the channel engagement flanges 559 disengage the second closure cam surfaces 1727′, the channel engagement flanges 559 engage corresponding third closure surfaces 1728′ on the bottom of the channel 1720 to keep the anvil assembly and cartridge assembly closed throughout the firing process (i.e., as the dynamic I-beam clamping assembly is distally advanced through the cartridge assembly 701′ to its ending position).

In the illustrated arrangement, when the dynamic I-beam clamping assembly 550 is in the proximal most or starting position, the channel engagement tabs 559 are located in abutting engagement with the second closure cam surfaces 1727′ and are not spaced therefrom. Thus, when the dynamic I-beam clamping assembly is actuated to move distally, the channel engagement flanges 559 immediately start to cam the cartridge assembly 701′ closed. Such arrangement provides a jaw aperture angle Θ₂ that is greater than Θ₁, for example. Thus, unlike the second jaw 700 described above, the dynamic I-beam clamping assembly 550 does not move distally any distance before it begins to cam the second jaw 700′ closed. In that arrangement, the actuation sled 1712′ has a length SL′ and a nose portion 718′ that has a length NL′ that extends beyond the distal end of the channel 1720′. When compared to the above described arrangement, SL′<SL and NL′<NL, which generally leads to improved maneuverability of the end effector 1500′. In other arrangements, there is at least a portion of the I-beam clamping assembly distal advancement wherein the I-beam clamping assembly is not in contact with both jaws before it enters its closure strike portion wherein it begins to oppose the jaws toward one another.

During the firing process, a considerable amount of friction is generally experienced between the dynamic clamping assembly and the anvil assembly and cartridge assembly. Typically, the dynamic clamping assembly is fabricated from steel and employs steel pins or flanges for contacting the corresponding ledges on the anvil plate and the channel which are also fabricated from steel. As dynamic clamping member is advanced distally, the upper and lower steel pins are brought into slidable frictional contact with the corresponding ledges on the anvil plate and channel to clamp the anvil assembly and cartridge assembly onto the target tissue and drive the actuation sled distally to fire the staples and cut the stapled tissue. Such frictional contact can often result in the erosion of the steel pins and ledges which can significantly reduce the useful life of the end effector. In addition, the increased friction between the pins or flanges of the dynamic clamping assembly and the anvil assembly and cartridge assembly increases the amount of firing force that is required to drive the dynamic clamping assembly from its starting to ending position through the clamped tissue. These large firing forces dictate that the related components within the end effector as well as within the adapter must be sufficiently capable of accommodating such high firing forces. This requires that the various components be manufactured from stronger and often thicker material in an operational environment where operational space is limited (e.g., within the outer tube of the adapter). Thus, higher firing forces lead to more complicated designs and material compositions which lead to increased instrument costs.

Another aspect of the present disclosure comprises a dynamic clamping assembly 1550 as illustrated in FIG. 35. In the illustrated example, the dynamic clamping assembly 1550 comprises a vertically extending body portion 1552 that has a tissue cutting portion 1554 formed therein. The body portion 1552 is sized to be slidably received within the elongate slot 622 of the anvil plate 620 (FIG. 10) as well as within the central slot 724 of the channel 720 (FIG. 15). The cartridge assembly 701 generally includes a proximal end 705 and a distal end and 707 and defines a longitudinal axis LA therebetween. See FIGS. 10 and 15. The dynamic clamping assembly 1550 further includes at least one channel engagement feature 1558. In the illustrated arrangement, a channel engagement feature 1558 extends from each lateral side 1553 of the body portion 1552. In one example, each channel engagement feature 1558 comprises a channel engagement flange 1580 that has a distal end 1582, a proximal end 1584, and a channel ledge engagement surface 1586 extending therebetween. The channel ledge engagement surface 1586 is configured to slidably ride on or engage a corresponding one of the channel ledges 725 formed on each side of the central slot 724 in the channel 720. In the illustrated arrangement, a distal end 1587 of the channel ledge engagement surface 1586 is radiused to reduce friction between the channel ledge engagement surface 1586 and the channel ledges 725. In accordance with another aspect, in at least one arrangement, the channel ledge engagement surface 1586 angles from the proximal end 1584 to the distal end 1584 away from the longitudinal axis LA. For example, in FIG. 35, axis CLA is parallel to the longitudinal axis LA and may also be parallel to the upper surface 729 of each channel ledge 725 when the cartridge assembly 701 is in the closed position. In at least one arrangement, for example, the channel ledge engagement surface 1586 angles away from axis CLA a channel angle Θ_(CA). Stated another way, the channel ledge engagement surface 1586 is not parallel with the upper surface 729 of a corresponding one of the channel ledges 725 when the cartridge assembly 701 is in the closed position. In one arrangement, Θ_(CA) may be approximately 0.5°, for example. Other angles, however, are contemplated. Such arrangement may lower point loads on the distal end 1582 of the flange 1580. In an alternative arrangement (not shown), the anvil engagement surface on each of the anvil engagement flanges may have two distinct linear segments wherein one segment is arranged at an angle of the positive anvil opening ramps 628 (FIGS. 27-29) and the other linear segment may match the angle of each of the anvil plate ledges 624. In still other alternative arrangements (not shown) the length of each of the channel engagement flanges may be longer than the length of the anvil engagement flanges which may allow the loads to be distributed over a larger area of the channel ledge which may lower the potential local contact loads and lower galling. Similar favorable results may be obtained wherein each of the anvil engagement flanges are longer than the channel engagement flanges.

Still referring to FIG. 35, the dynamic clamping assembly 1550 further includes at least one anvil engagement feature 1556. In the illustrated arrangement, an anvil engagement feature 1556 extends from each lateral side 1553 of the body portion 1552. In one example, each anvil engagement feature 1556 comprises a flange 1590 that has a distal end 1592, a proximal end 1594 and an anvil ledge engagement surface 1596 extending therebetween. The anvil ledge engagement surface 1596 is configured to slidably ride on or engage a corresponding one of the anvil plate ledges 624 formed on each side of the elongate slot 622 in the anvil plate 620. In the illustrated arrangement, a distal end 1597 of the anvil ledge engagement surface 1596 is radiused to reduce friction between the anvil ledge engagement surface 1596 and the anvil plate ledges 624. In accordance with another aspect, in at least one arrangement, the anvil ledge engagement surface 1596 angles from the proximal end 1594 to the distal end 1592 away from the longitudinal axis LA. For example, in FIG. 35, axis ALA is parallel to the longitudinal axis LA and may also be parallel to the lower surface 626 of each anvil plate ledge 624 when the anvil assembly 612 is in the closed position. In at least one arrangement, for example, the anvil ledge engagement surface 1596 angles away from axis ALA an anvil angle Θ_(AA). Stated another way, the anvil ledge engagement surface 1596 is not parallel with the lower surface of a corresponding one of the anvil plate ledges 624 when the anvil plate 620 is in the closed position. In one arrangement, Θ_(AA) may be approximately 1°, for example. Other angles, however, are contemplated. Such arrangement may lower the point loads on the distal end 1592 of the flange 1590. Other arrangements are contemplated wherein only the channel ledge engagement surfaces or the anvil ledge engagement surfaces are angled. For example, in another arrangement, the channel ledge engagement surface of each channel engagement flange may be approximately parallel to the longitudinal axis LA and the anvil ledge engagement surface on each of the anvil ledge engagement flanges are angles as described herein. In another arrangement, the channel ledge engagement surface of each channel ledge engagement flange is angled as described above, but the anvil ledge engagement surface of each anvil engagement flange is not angled relative to the longitudinal axis LA, but rather is approximately parallel thereto.

Turning to FIG. 36, in accordance with yet another aspect of the present disclosure, each of the anvil engagement flanges 1590 is coated with a ceramic material 1598. One form of ceramic coating that may be employed comprises ceramic coatings that may comprise, for example, diamond-like carbon (DLC), titanium nitride (TiN), zirconium nitride (ZrN), titanium-niobium-nitride (TiNbN), calcium phosphates (Ca₃(PO₄)₂), and a hydroxyapatite (Ca₁₀(PO₄)6°(OH)₂). Although not strictly regarded as a coating(but as a native oxide layer), another popular metallic-ceramic composite is an in-situ grown monoclimic zirconia onto a zirconium niobium alloy (i.e., oxidized zirconia, OxZr). A similar coating may be applied to each of the channel engagement flanges 1580. In addition, a similar ceramic coating may be applied to the lower surface 626 of each of the anvil plate ledges 624 as well as to the upper surface 729 of each channel ledge 725. In the alternative, the entire anvil plate ledges 624 and the entire channel ledges 725 may be coated with the ceramic coating. Such coating may be applied using 3D printing technology and form a surface with significantly higher hardness than the material to which it is applied and can also be highly polished to result in significantly lower frictional drag between those components during firing. Other methods of applying coatings that may be effectively employed include but are not limited to indirect resin composite—aerosol deposition as well as plasma and vapor deposition.

In accordance with another general aspect of the present disclosure, one form of the dynamic clamping member 1550 includes at least one channel flange insert 1585 that is embedded into the corresponding channel engagement flange 1580. In the illustrated example, two channel flange inserts 1585 are embedded into each channel flange 1580. Still referring to FIG. 36, the dynamic clamping member 1550 further includes at least one anvil flange insert 1595 that is embedded into the corresponding anvil engagement flange 1590. In the illustrated example, two anvil flange inserts 1595 are embedded into each anvil flange 1590. As shown, each channel flange insert 1585 and each anvil flange insert 1595 has a rectangular cross-sectional shape. However, other numbers, sizes and shapes of channel flange and anvil flange inserts are contemplated. In at least one example, each anvil flange insert 1595 extends from the outer coating or cover 1598.

In accordance with another general aspect, for those arrangements wherein each channel ledge 725 and each anvil plate ledge 624 is fabricated from metal (or other material) having, for example, a hardness measured on the Rockwell C scale of approximately HRC 39-45, each of the channel flange inserts 1585 and each of the anvil flange inserts 1595 may be fabricated from a material having a hardness value that is greater than the hardness value of the channel ledges 725 and the anvil plate ledges 624. For example, the channel flange inserts 1585 and the anvil flange inserts 1595 may be fabricated from ceramic materials that include, but are not limited to for example, alumina (Al₂O₃), zirconia (ZrO₂), zirconia-toughened alumina (ZTA), alumina matrix composites (AMC), alumina-toughened zirconia (ATZ), silicon nitride (Si₃N₄), and hydroxyapatite (Hap) that has a hardness value of approximately HRC 55-70. In these instances, the material comprising the channel flange inserts and the anvil flange inserts has a crystalline structure that differs from the crystalline structure(s) of the material(s) from which the anvil plate ledges and channel ledges are fabricated.

FIG. 37 is a cross-sectional view of the central body portion 1552 of the dynamic clamping assembly 1550 taken along line 37-37 in FIG. 36. In the illustrated example, the central body portion 1552 comprises a central region 1555 that may be fabricated from 420 or 440 SS—high Rockwell C 400 series stainless steel. A ceramic side region 1559 is attached to each lateral side of the central region. Each ceramic side region may have a hardness that is greater than the hardness of the central region. Hardened inserts 1551 are also attached to the surfaces of the ceramic side regions. The hardened inserts may be fabricated from 420 or 440 SS—high Rockwell C 400 series stainless steel.

FIGS. 38 and 39 illustrate another dynamic clamping assembly 1550′ that is similar to the dynamic clamping assembly 1550 except for the differences discussed below. As can be seen in FIG. 38, a channel ledge engagement surface 1586′ of a channel engagement flange 1580′ and an anvil ledge engagement surface 1596′ of an anvil engagement flange 1590′ are each approximately parallel to the longitudinal axis LA. Each of the channel engagement flanges 1580′ as well as a body portion 1552 of the dynamic clamping assembly 1550′ are coated with a material 1560 that may comprise a coating material sold under the trademark MEDCOAT/2000™ by the Electrolizing Corporation of Ohio. In the alternative, a Nitride coating may be employed. These coatings may be applied after the tissue cutting portion 1554 has been formed and sharpened. Applying the coating of material 1560 to the tissue cutting portion 1554 may enhance and improve its sharpness.

FIGS. 40-43 depict an articulation locking system 5900 for locking an articulation link 5560 of a surgical end effector 5500 in the form of a loading unit 5510 (DLU or MLU). The loading unit 5510 is identical to the loading unit 510 except for the differences noted below. As can be seen in FIGS. 40-43, the illustrated articulation locking system 5900 comprises a laterally displaceable lock member 5910 that includes lock teeth 5912 that are configured to lockingly engage lock grooves 5564 formed in a proximal end 5562 of the articulation link 5560. The locking system 5900 further comprises a locking cam 5920 that is pivotally coupled to an outer housing 5532. Outer housing 5532 is similar to outer housing 532 described above. The lock member 5910 is constrained to move laterally (directions L₁ and L₂) between two mounting features 5918 mounted or formed within the outer housing 5532 as can be seen in FIGS. 42 and 43. The locking cam 5920 includes a cam actuator 5922 that is configured to operably interface with a flexible drive beam 5542 of a drive assembly 5540. As can be most particularly seen in FIG. 40, a cam opening 5543 is provided in the flexible drive beam 5542 for receiving the cam actuator 5922 when the drive assembly 5540 is in the unactuated or unfired position. When in a starting or unfired position, the locking cam 5920 is biased into an unactuated position by a pair of biasing members 5940 that bear upon the lock member 5910 to laterally displace the lock member 5910 in the lateral direction L₁. When in that position, the lock teeth 5912 of the lock member 5910 are out of engagement with the lock grooves 5564 formed in the proximal end 5562 of the articulation link 5560 such that the articulation link 5560 may be axially moved in the proximal direction PD and distal direction DD by the articulation bar 258 of an adapter to which the end effector 5500 is operably attached. Thus, when in the unlocked position illustrated in FIG. 42, the articulation link 5560 may be axially moved to articulate the end effector into a desired articulated position. Once the clinician has articulated the end effector into the desired orientation, the drive assembly 5540 is actuated to distally advance the flexible firing beam 5542. As the firing beam 5542 is advanced distally, the cam actuator 5922 causes the locking cam 5920 to pivot and bias the lock member 5910 in the lateral direction L₂ so as to bring the locking teeth 5912 thereof into locking engagement with the lock grooves 5564. As can be seen in FIGS. 40-43, the lock grooves 5564 are defined between lock teeth 5566. The lock teeth 5566 each have pointed ends 5568 that are configured to cooperate with pointed ends 5914 on lock teeth 5912 to provide axial lead in assistance into the locked position.

FIGS. 44-54 illustrate a drive assembly locking system 6900 for preventing the axial advancement of a dynamic clamping assembly 550 of a surgical end effector 500′ unless an unfired cartridge 702 has been properly loaded into the channel 720 of the end effector 500′, for example. As used in this context, the term “unfired cartridge” means that the cartridge 702 has not been fired and contains all of its staples 704 with the actuation sled 712 in its starting and unfired or ready to fire position therein. As can be seen in FIG. 44, in one example, the drive assembly locking system 6900 comprises lock member 6902 that is supported by an inner housing 534 of the end effector 500′ and is configured to retainingly engage a body portion 552 of a dynamic clamping assembly 550. As can be seen in FIGS. 45-47, the lock member 6902 comprises two lateral lock arms 6904 that each has a latch feature 6906 thereon. The lateral lock arms 6904 are normally biased inward such that the latch features 6906 thereon retainingly engage the body portion 552 of the dynamic clamping assembly 550 when the dynamic clamping assembly 550 is located in its starting/unfired position. Thus, when the latch features 6906 are in retaining engagement with the dynamic clamping assembly 550, the dynamic clamping assembly 550 is prevented from being driven distally (fired).

FIGS. 44 and 45 illustrate a portion of the end effector 500′ wherein an unfired cartridge 702 has been properly loaded into the end effector 500′. The unfired cartridge 702 supports an actuator sled 712 in an unactuated position therein wherein portions of cam wedges 713 of the actuator sled 712 engage the latch features 6906 and bias each of the lateral lock arms 6904 out of locking engagement (arrows UL in FIG. 45) with the body portion 552 of the dynamic clamping assembly 550. When in that unlocked position (FIGS. 45 and 46), the dynamic clamping assembly 550 can be driven distally to fire the staples in the cartridge 702 (FIG. 47) and cut the tissue clamped therein. Once the dynamic clamping assembly 550 has been distally driven to its ending position within the cartridge 702, it is then retracted in the proximal direction PD back to its starting position. The actuation sled 712 remains at the distal end of the cartridge 702.

FIG. 48 illustrates the lock member 6902 after the dynamic clamping member has been driven distally out of its starting position. As can be seen in that Figure, the lock arms 6902 are biased inwardly (arrows LD). During the retraction process, the dynamic clamping assembly 550 will contact the latch features 6906 as it is retracted in the proximal direction PD as shown in FIG. 49. As the dynamic clamping assembly 550 contacts the latch features 6906, the lock arms 6904 are biased laterally outward (arrows UL) until the dynamic clamping assembly 550 is fully retracted into the starting position at which point the lock arms 6904 move back to the locked configuration wherein the latch features 6906 once again retainingly engage the dynamic clamping assembly 550. See FIG. 50. Thus, the dynamic clamping assembly 550 is once again prevented from being driven distally until a new unfired cartridge is loaded into the channel. Should the clinician attempt to refire the dynamic clamping member 550 before the now spent cartridge is replaced, they will be unable to do so. Further, should the clinician unwittingly load a partially fired cartridge into the end effector 500′, the lock member 6902 will prevent the dynamic clamping assembly 550 from being fired, because the actuation sled in the partially fired cartridge will not be in the starting position to unlock the lock member 6902. FIG. 51 illustrates the end effector 500′ with the jaws 610, 700 in the fully open position. FIG. 52 illustrates the dynamic clamping assembly 550 in a position corresponding to the fully open position. FIG. 53 illustrates the end effector 500′ with the jaws 610, 700 in the fully closed position. FIG. 54 illustrates the position of the dynamic clamping assembly 550 after it has moved the jaws 610, 700 to the fully closed position but prior to firing. Because the jaws 610, 700 are moved from the fully open to fully closed position by the dynamic clamping assembly 550, the lock member 6902 is configured to permit such axial movement of the dynamic clamping assembly 550 while still being in the locked position. As can be seen in FIGS. 52 and 54, for example, when the lock arms 6904 are in the normally locked position, an axial pocket 6908 is defined therebetween to permit the axial movement of the dynamic clamping assembly 550 that is required to open and close the jaws 610, 700 without permitting the dynamic clamping assembly 550 from being distally moved beyond the fully closed position unless an unfired cartridge is loaded into the channel of the end effector.

FIGS. 55-57 illustrate another drive assembly locking system 6920 for preventing the axial advancement of the dynamic clamping assembly 550 of an end effector of an adapter of the type disclosed herein unless a cartridge 702′ has been properly loaded into the channel of the end effector. In this example, the cartridge 702′ is formed with a pair of proximally extending unlocking features 6930 that are configured to unlocking engage a pivoting lock member 6922. The pivoting lock member 6922 is configured to pivot between a locked position wherein a lockout feature 6924 is received within a lock cavity 543′ that is formed in a flexible drive beam 542′ (FIG. 55) of the end effector. When the lockout feature 6924 is received within the lock cavity 543′, the drive beam 542′ (and the dynamic clamping assembly 550 coupled thereto) cannot be advanced distally to fire staples that are stored in the cartridge 702′. The lock member 6922 also includes a distally extending unlocking arm 6926 that corresponds to each unlocking feature 6930 on the cartridge 702′. When the cartridge 702′is properly loaded into the end effector, the unlocking features 6930 engage the corresponding unlocking arms 6926 to pivot the lock member 6922 to the unlocked position wherein the lockout feature 6924 is pivoted out of the lock cavity 543 to thereby permit the drive beam 542′ to be distally advanced to fire the dynamic clamping assembly 550. In an alternative arrangement, the proximally extending unlocking features 6930 are not formed on the cartridge 702, but instead are formed on the actuation sled (not shown) that is supported in the cartridge. When the actuation sled is in the unactuated position (corresponding to an unfired or fresh cartridge) the unlocking features thereon will engage the unlocking arms 6926 on the lock member 6922 to pivot the lock member into the unlocked position.

FIG. 58 illustrates another cartridge 702″ arrangement that employs a flexible circuit member 6940 that is attached to a deck surface 6952 of the cartridge body 6950. In the illustrated arrangement, a raised deck portion 6954 extends on each side of an elongate slot 6951 in the cartridge body 6950 to detect the position of a dynamic clamping member of the end effector. The flexible circuit 6940 may include a circuit microchip 6942 that communicates with the circuit board 294 in the adapter in which it is mounted. The flexible circuit member 6940 includes contacts 6944 that electrically contact corresponding contacts (not shown) in a channel of the end effector which are ultimately connected to a circuit board 294 (FIG. 6) of an adapter or other control board arrangement therein. The flexible circuit member 6940 may facilitate better control of the advancement of the dynamic clamping assembly by monitoring its location and using that information to control a firing motor in the surgical instrument. For example, such arrangement may be employed to change the speed or power capability at the beginning or end of the firing stroke. This information may also be used to change the maximum acceptable torque limits at the very beginning of the firing stroke and at the end of the firing stroke. In other arrangements, a deformable member may be provided within the MULU opening for the distal end of the firing rod which could allow for a shock absorbing stop at the end of the stroke but also as a leading force indicator on the current of the motor as the rod gets near the ends of its metallic slot travel. Placement of a portion of the MULU or DLU which has a high moment of inertia but also a higher elastic strain capability would allow this part of the ground force return system to absorb any high force spikes that occur due to the motor's inability to dynamically brake fast enough in case of a series of metallic components inadvertently colliding. This elongateable and preferably elastic component may be in series with the ground and DLU bayonet attachment. Such arrangement may comprise plastic bendable features that exist at the attachment point of the metal articulation pivot I-plates. Such arrangement may also comprise a separate part in cooperation with these attachments and the bayonet connection which has a stretchable aspect with maximum stretch limiting secondary features that allow for limited stretch length but tolerate impact deflections.

EXAMPLES

Example 1—A dynamic clamping assembly for use with a surgical instrument that includes first and second jaws that are pivotally coupled together and movable between open and closed positions. In at least one example, the dynamic clamping assembly comprises a body portion that has at least one first jaw engagement feature protruding therefrom and is configured to slidably engage a corresponding first jaw ledge that is formed in the first jaw to apply closing motions thereto. The body portion further includes at least one second jaw engagement feature that protrudes therefrom and is configured to slidably engage a corresponding second jaw ledge formed in the second jaw to apply other closing motions thereto. A surface coating is provided on at least a portion of each first jaw engagement feature to increase a hardness thereof.

Example 2—The dynamic clamping assembly of Example 1, wherein the surface coating is on at least a portion of each second jaw engagement feature to increase another hardness thereof.

Example 3—The dynamic clamping assembly of Examples 1 or 2, wherein the body portion comprises a tissue cutting edge and wherein the surface coating is on the tissue cutting edge to increase a sharpness thereof.

Example 4—The dynamic clamping assembly of Examples 1, 2 or 3, wherein the first jaw engagement feature comprises a first planar flange that protrudes from a first lateral side of the body portion and a second planar flange that protrudes from a second lateral side of the body portion and wherein each first and second planar flanges is completely coated with the surface coating.

Example 5—The dynamic clamping assembly of Examples 1, 2, 3 or 4, wherein the second jaw engagement feature comprises a first lower planar flange that protrudes from the first lateral side of the body portion and a second lower planar flange that protrudes from the second lateral side of the body portion and wherein each first and second lower planar flanges is completely coated with the surface coating.

Example 6—The dynamic clamping assembly of Examples 1, 2, 3, 4 or 5, wherein the second jaw defines a second longitudinal axis that extends between a second proximal end and a second distal end and wherein each second jaw engagement feature comprises a second feature closure surface that is configured to engage the corresponding second jaw ledge and is arranged at a second engagement angle relative to the second longitudinal axis.

Example 7—The dynamic clamping assembly of Examples 1, 2, 3, 4, 5 or 6, wherein the second jaw engagement feature comprises a second feature closure surface that is not parallel to a second jaw ledge surface of a corresponding second jaw ledge.

Example 8—The dynamic clamping assembly of Examples 1, 2, 3, 4, 5, 6 or 7, wherein the surface coating comprises a titanium nitride coating material.

Example 9—The dynamic clamping assembly of Examples 1, 2, 3, 4, 5, 6, 7 or 8, wherein the first jaw defines a first longitudinal axis that extends between a first proximal end and a second distal end and wherein each first jaw engagement feature comprises a first feature closure surface that is configured to engage the corresponding first jaw ledge and is arranged at a first engagement angle relative to the first longitudinal axis.

Example 10—The dynamic clamping assembly of Examples 1, 2, 3, 4, 5, 6, 7, 8 or 9, wherein the first jaw engagement feature comprises a first feature closure surface that is not parallel to a first jaw ledge surface of a corresponding first jaw ledge.

Example 11—A surgical end effector that comprises an anvil assembly that includes at least one anvil closure ledge. A channel is configured to operably support a fastener cartridge therein and is movably coupled to the anvil assembly such that the anvil assembly and the channel may be oriented relative to each other between open and closed positions. The channel includes at least one channel closure ledge. The end effector further comprises a dynamic clamping assembly that comprises a body portion that has at least one anvil engagement feature protruding therefrom. The anvil engagement feature is configured to slidably engage a corresponding anvil closure ledge to apply closing motions thereto. The body portion further includes at least one channel engagement feature that protrudes therefrom and is configured to slidably engage a corresponding channel closure ledge to apply other closing motions thereto. A surface coating is provided on at least a portion of each anvil engagement feature to increase a hardness thereof.

Example 12—The surgical end effector of Example 11, wherein the surface coating is on at least a portion of each channel engagement feature to increase another hardness thereof.

Example 13—The surgical end effector of Examples 11 or 12, wherein the body portion comprises a tissue cutting edge and wherein the surface coating is on the tissue cutting edge to increase a sharpness thereof.

Example 14—The surgical end effector of Examples 11, 12 or 13, wherein the anvil engagement feature comprises a first planar flange that protrudes from a first lateral side of the body portion and a second planar flange that protrudes from a second lateral side of the body portion and wherein each of the first and second planar flanges are completely coated with the surface coating.

Example 15—The surgical end effector of Examples 11, 12, 13 or 14, wherein the channel engagement feature comprises a primary planar flange that protrudes from the first lateral side of the body portion and a secondary planar flange that protrudes from the second lateral side of the body portion and wherein each primary and secondary planar flanges is completely coated with the surface coating.

Example 16—The surgical end effector of Examples 11, 12, 13, 14 or 15, wherein the anvil assembly defines a first longitudinal axis that extends between a first proximal end and a second distal end and wherein each anvil engagement feature comprises an anvil closure surface that is configured to engage the corresponding anvil closure ledge and is arranged at a first engagement angle that is relative to the first longitudinal axis.

Example 17—The surgical end effector of Examples 11, 12, 13, 14, 15 or 16, wherein the anvil engagement feature comprises an anvil closure surface that is not parallel to an anvil ledge surface of a corresponding anvil ledge.

Example 18—The surgical end effector of Examples 11, 12, 13, 14, 15, 16 or 17, wherein the channel defines a second longitudinal axis that extends between a second proximal end and a second distal end and wherein each channel engagement feature comprises a channel closure surface that is configured to engage the corresponding channel closure ledge and is arranged at a second engagement angle that is relative to the second longitudinal axis.

Example 19—The surgical end effector of Examples 11, 12, 13, 14, 15, 16, 17 or 18, wherein each channel engagement feature comprises a channel closure surface that is not parallel to a channel ledge surface of a corresponding channel closure ledge.

Example 20—The surgical end effector of Examples 11, 12, 13, 14, 15, 16, 17, 18 or 19, wherein the surface coating comprises a titanium nitride coating material.

Many of the surgical instrument systems described herein are motivated by an electric motor; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example. In certain instances, the motors disclosed herein may comprise a portion or portions of a robotically controlled system. Moreover, any of the end effectors and/or tool assemblies disclosed herein can be utilized with a robotic surgical instrument system. U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, discloses several examples of a robotic surgical instrument system in greater detail.

The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not so limited. Various embodiments are envisioned which deploy fasteners other than staples, such as clamps or tacks, for example. Moreover, various embodiments are envisioned which utilize any suitable means for sealing tissue. For instance, an end effector in accordance with various embodiments can comprise electrodes configured to heat and seal the tissue. Also, for instance, an end effector in accordance with certain embodiments can apply vibrational energy to seal the tissue.

Although various devices have been described herein in connection with certain embodiments, modifications and variations to those embodiments may be implemented. Particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined in whole or in part, with the features, structures or characteristics of one ore more other embodiments without limitation. Also, where materials are disclosed for certain components, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, to perform a given function or functions. The foregoing description and following claims are intended to cover all such modification and variations.

The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, a device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps including, but not limited to, the disassembly of the device, followed by cleaning or replacement of particular pieces of the device, and subsequent reassembly of the device. In particular, a reconditioning facility and/or surgical team can disassemble a device and, after cleaning and/or replacing particular parts of the device, the device can be reassembled for subsequent use. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

The devices disclosed herein may be processed before surgery. First, a new or used instrument may be obtained and, when necessary, cleaned. The instrument may then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and instrument may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, and/or high-energy electrons. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument may then be stored in the sterile container. The sealed container may keep the instrument sterile until it is opened in a medical facility. A device may also be sterilized using any other technique known in the art, including but not limited to beta radiation, gamma radiation, ethylene oxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of the disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. 

What is claimed is:
 1. A dynamic clamping assembly for use with a surgical instrument including first and second jaws pivotally coupled together and movable between open and closed positions, said dynamic clamping assembly comprising: a body portion; at least one first jaw engagement feature protruding from said body portion and configured to slidably engage a corresponding first jaw ledge formed in the first jaw to apply closing motions thereto; at least one second jaw engagement feature protruding from said body portion and configured to slidably engage a corresponding second jaw ledge formed in the second jaw to apply other closing motions thereto; and a surface coating on at least a portion of each said at least one first jaw engagement feature to increase a hardness thereof.
 2. The dynamic clamping assembly of claim 1, wherein said surface coating is on at least a portion of each said at least one second jaw engagement feature to increase another hardness thereof.
 3. The dynamic clamping assembly of claim 1, wherein said body portion comprises a tissue cutting edge and wherein said surface coating is on said tissue cutting edge to increase a sharpness thereof.
 4. The dynamic clamping assembly of claim 1, wherein said at least one said first jaw engagement feature comprises: a first planar flange protruding from a first lateral side of said body portion; and a second planar flange protruding from a second lateral side of said body portion and wherein each of said first and second planar flanges is completely coated with said surface coating.
 5. The dynamic clamping assembly of claim 4, wherein said at least one second jaw engagement feature comprises: a first lower planar flange protruding from said first lateral side of said body portion; and a second lower planar flange protruding from said second lateral side of said body portion and wherein each of said first and second lower planar flanges is completely coated with said surface coating.
 6. The dynamic clamping assembly of claim 1, wherein the second jaw defines a second longitudinal axis extending between a second proximal end and a second distal end and wherein each said second jaw engagement feature comprises a second feature closure surface configured to engage the corresponding second jaw ledge and arranged at a second engagement angle relative to the second longitudinal axis.
 7. The dynamic clamping assembly of claim 1, wherein each said second jaw engagement feature comprises a second feature closure surface that is not parallel to a second jaw ledge surface of a corresponding second jaw ledge.
 8. The dynamic clamping assembly of claim 1, wherein said surface coating comprises a titanium nitride coating material.
 9. The dynamic clamping assembly of claim 1, wherein the first jaw defines a first longitudinal axis extending between a first proximal end and a second distal end and wherein each said first jaw engagement feature comprises a first feature closure surface configured to engage the corresponding first jaw ledge and arranged at a first engagement angle relative to the first longitudinal axis.
 10. The dynamic clamping assembly of claim 1, wherein each said first jaw engagement feature comprises a first feature closure surface that is not parallel to a first jaw ledge surface of a corresponding first jaw ledge.
 11. A surgical end effector, comprising: an anvil assembly comprising at least one anvil closure ledge; a channel configured to operably support a fastener cartridge therein and movably coupled to said anvil assembly such that said anvil assembly and said channel may be oriented relative to each other between open and closed positions, said channel comprising at least one channel closure ledge; a dynamic clamping assembly, comprising: a body portion; at least one anvil engagement feature protruding from said body portion and configured to slidably engage a corresponding one of said at least one anvil closure ledge to apply closing motions thereto; at least one channel engagement feature protruding from said body portion and configured to slidably engage a corresponding one of said at least one channel closure ledge to apply other closing motions thereto; and a surface coating on at least a portion of each said anvil engagement feature to increase a hardness thereof.
 12. The surgical end effector of claim 11, wherein said surface coating is on at least a portion of each said channel engagement feature to increase another hardness thereof.
 13. The surgical end effector of claim 11, wherein said body portion comprises a tissue cutting edge and wherein said surface coating is on said tissue cutting edge to increase a sharpness thereof.
 14. The surgical end effector of claim 11, wherein said at least one said anvil engagement feature comprises: a first planar flange protruding from a first lateral side of said body portion; and a second planar flange protruding from a second lateral side of said body portion and wherein each of said first and second planar flanges is completely coated with said surface coating.
 15. The surgical end effector of claim 14, wherein said at least one channel engagement feature comprises: a primary planar flange protruding from said first lateral side of said body portion; and a secondary planar flange protruding from said second lateral side of said body portion and wherein each of said primary and secondary planar flanges is completely coated with said surface coating.
 16. The surgical end effector of claim 11, wherein said anvil assembly defines a first longitudinal axis extending between a first proximal end and a second distal end and wherein each said anvil engagement feature comprises an anvil closure surface configured to engage the corresponding anvil closure ledge and arranged at a first engagement angle relative to the first longitudinal axis.
 17. The surgical end effector of claim 11, wherein each said anvil engagement feature comprises an anvil closure surface that is not parallel to an anvil ledge surface of a corresponding anvil ledge.
 18. The surgical end effector of claim 16, wherein said channel defines a second longitudinal axis extending between a second proximal end and a second distal end and wherein each said channel engagement feature comprises a channel closure surface configured to engage the corresponding channel closure ledge and arranged at a second engagement angle relative to the second longitudinal axis.
 19. The surgical end effector of claim 17, wherein each said channel engagement feature comprises a channel closure surface that is not parallel to a channel ledge surface of a corresponding channel closure ledge.
 20. The surgical end effector of claim 11, wherein said surface coating comprises a titanium nitride coating material. 